CN114729480B

CN114729480B - Knitted components with foam surface features

Info

Publication number: CN114729480B
Application number: CN202080080566.3A
Authority: CN
Inventors: 奥斯汀·巴朗尼克; 凯瑟琳·弗雷泽; 斯蒂芬·J·希普; J·莫里纽克斯; 克里斯汀·E·奥姆; 玛格丽特·P·圣克莱尔; 赵阳
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2019-11-18
Filing date: 2020-11-18
Publication date: 2025-01-03
Anticipated expiration: 2040-11-18
Also published as: EP4041944A1; WO2021101979A1; WO2021101979A8; CN114729480A; US20210148017A1; US12180625B2; EP4155444A1; EP4041944B1

Abstract

A knitted component includes a first region, wherein the first region includes more than one knitted loop including a first yarn. The knitted component also includes a second yarn at least partially embedded within the first region of the knitted component such that the second yarn extends between at least the first loop and the second loop of the more than one knitted loop. The second yarn has a foamable material comprising a blowing agent and a thermoplastic polymer.

Description

Knitted component with foam surface features

RELATED APPLICATIONS

The present application claims the benefit of four (4) U.S. provisional patent applications, U.S. provisional patent application No. 62/937,133 filed on 11 months and 18 days of 2019, U.S. provisional patent application No. 62/937,117 filed on 11 months and 18 days of 2019, U.S. provisional patent application No. 62/937,092 filed on 11 months and 18 days of 2019, and U.S. provisional patent application No. 62/939,110 filed on 11 months and 22 days of 2019. Each of the patent applications listed in this paragraph is hereby incorporated by reference in its entirety.

Technical Field

The present disclosure relates generally to knitted components (knitted component) and methods of manufacturing knitted components, such as knitted components for footwear applications, apparel applications, or the like.

Background

A variety of articles are formed from textiles. For example, articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other coats, underpants and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, vehicle seats) are typically formed at least in part from textiles. These textiles are typically formed from a woven (weaving) or interlooping (interlooping) (e.g., knit (knitting)) yarn or yarns, which is typically accomplished through mechanical processes involving a loom or knitting machine. One particular object that may be formed from textiles is an upper for an article of footwear.

Knitting is an example of a process by which textiles can be formed. Knitting may generally be classified as weft knitting or warp knitting. In both weft knitting and warp knitting, one or more yarns are manipulated to form more than one intermeshed loop (INTERMESHED LOOPS) defining a plurality of courses (courses) and wales (wales). In more general weft knitting, the courses and wales are perpendicular to each other and may be formed from a single yarn or a plurality of yarns. In warp knitting, the wales and courses extend substantially parallel (run).

Although knitting can be performed by hand, commercial manufacture of knitted components is typically performed by knitting machines. An example of a knitting machine for producing weft knitted components is a V-bed flat knitting machine (V-bed FLAT KNITTING MACHINE) comprising two needle beds angled relative to each other. The rail extends over and parallel to the needle bed and provides an attachment point for a feeder (feeder) that moves along the needle bed and supplies yarn to the needles within the needle bed. Standard feeders have the ability to supply yarn that is used for knitting (knit), tucking (tuck), and floating (float). In the case where the inlay yarn (INLAY YARN) is incorporated into a knitted component, an inlay feeder (INLAY FEEDER) is typically used.

Brief Description of Drawings

Embodiments of the present disclosure may be better understood with reference to the following drawings and description. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. Furthermore, in the drawings, like reference numerals designate similar or identical features in some cases.

Fig. 1 is a diagram illustrating a knitted component including embedded foamable yarns in accordance with certain aspects of the present disclosure.

Fig. 2 is a diagram illustrating an article having knitted components with foam protrusions (foam protrusion) extending from a surface thereof, according to certain aspects of the present disclosure.

Fig. 3 is a diagram illustrating an article having knitted components with foam protrusions extending from a surface thereof, according to certain aspects of the present disclosure.

Fig. 4 is a diagram illustrating an article having knitted components and a foam surface in accordance with certain aspects of the present disclosure.

Fig. 5 is a diagram illustrating an article having knitted components with foam protrusions extending from a surface thereof, according to certain aspects of the present disclosure.

Fig. 6 is a diagram illustrating an article having knitted components with foam protrusions extending from a surface thereof, according to certain aspects of the present disclosure.

Fig. 7 is a diagram illustrating an article having a knitted component with a tubular knitted structure forming a bag in conjunction with a foamed interior of the bag in accordance with certain aspects of the present disclosure.

Fig. 8 is a diagram illustrating an upper for an article of footwear with embedded foamable yarns in accordance with certain aspects of the disclosure.

Fig. 9 is a diagram illustrating an upper for an article of footwear having knitted components and foam protrusions extending from a surface thereof in accordance with certain aspects of the present disclosure.

Fig. 10-14 are illustrations showing knitting diagrams for forming a knitted component with embedded foamable yarns in accordance with certain aspects of the present disclosure.

Detailed Description

Various aspects are described below with reference to the drawings, in which like elements are generally identified by like numerals. The relationship and functioning of the various elements of the various aspects are better understood by reference to the following detailed description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily to scale and that, in some instances, details that are not necessary for an understanding of the aspects disclosed herein, such as conventional fabrication and assembly, may have been omitted.

Embodiments of the present invention generally relate to textiles. A textile may be defined as a structure made of fibers, filaments or yarns characterized by flexibility, fineness (fineness) and a high ratio of length to thickness. Textiles generally fall into two categories. The first category includes textiles produced directly from a web of filaments or fibers by randomly (or non-randomly) interlocking or interconnecting to construct a nonwoven fabric and felt (felts). A second category includes textiles formed by mechanical manipulation of yarns (e.g., by interlacing or interlooping) to produce, for example, woven or knit fabrics.

The textile may include one or more yarns. Generally, a yarn is defined as an assembly of at least one filament or more than one fiber having a relatively long length and a relatively small cross-section. The fibers have a relatively short length and require a spinning or twisting process to produce a yarn of suitable length for use in textiles. Common examples of fibers are cotton and wool. However, filaments have an indefinite length and can only be combined with other filaments to produce yarns suitable for use in textiles. Modern filaments include more than one synthetic material, such as rayon (rayon), nylon, polyester, and polyacrylic, with filaments (silk) being the dominant, naturally occurring exception. Yarns may be formed from a single filament, conventionally referred to as a "single filament yarn (monofilament yarn)", or more than one individual filament grouped together. The yarn may also include individual filaments formed from different materials, or the yarn may include filaments each formed from two or more different materials. Similar concepts also apply to yarns formed from fibers. Thus, the yarn may have a variety of configurations that generally conform to the definition provided above.

While embodiments of the present invention may be formed with any type of textile, the following description generally refers to knitted textiles or "knitted components. For example, referring to fig. 1, certain articles may be formed at least partially as knitted component 100, and may potentially be formed entirely as knitted component 100. Advantageously, forming an article including knitted component 100 can impart advantageous advantages including, but not limited to, a particular degree of elasticity (e.g., expressed in terms of young's modulus), breathability, flexibility, strength, hygroscopicity, weight, abrasion resistance, and/or combinations thereof. These characteristics may be achieved by selecting a particular single layer knit structure or multi-layer knit structure (e.g., rib knit structure, single jersey knit structure (single jersey knit structure), or double jersey knit structure (double jersey knit structure)), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., polyester material, relatively inelastic material, or relatively elastic material such as elastic fibers (spandex)), by selecting yarns of a particular size (e.g., denier), and/or combinations thereof. The weight of the article (e.g., such as upper 300 as shown in fig. 8, and thus the total weight of the article of footwear) may be reduced relative to alternative articles (e.g., conventional non-knit uppers and/or other components commonly used in footwear). Knitted component 100 may also provide desired aesthetic characteristics by incorporating yarns having different colors, textures, or other visual properties arranged in a particular pattern. The yarns themselves and/or the knit structure formed by one or more yarns of the knitted component can be varied at different locations to provide different knitted portions having different properties.

In some embodiments, and referring to fig. 1, when knitted component 100 is knitted and removed from the knitting machine, knitted component 100 can include at least one foamable yarn 102. Further, knitted component 100 can include more than one first yarn 104 (e.g., where reference to "second yarn" can refer to foamable yarn 102) that forms more than one course and/or more than one intermeshed loop of knitted component 100. For example, the first yarn 104 may be formed of a polyester material and/or another suitable material as understood by those skilled in the art. The first yarn 104 may not be a foamable yarn. Foamable yarn 102 may be defined herein as a yarn comprising a foamable material, wherein the foamable material comprises a thermoplastic polymer and a blowing agent. An example of a foamable yarn is described in U.S. provisional application No. 62/937,092 filed on 11/18 2019 and entitled "FOAMABLE YARNS,TEXTILES AND ARTICLES INCORPERATING FOAMABLE YARNS,AND THE PROCESS OF MANUFACTURING THE SAME", which is incorporated into the above description.

As described herein, a thermoplastic material (e.g., thermoplastic polymer) is a substance that can become plastic when heated and harden without undergoing chemical transformation when cooled. The thermoplastic polymer may include natural polymeric materials, recycled materials, synthetic polymeric materials, or some combination thereof.

The natural polymeric material may be plant derived or animal derived. The plant-derived natural polymeric material may include cotton, flax, hemp, jute or similar materials. The animal derived natural polymeric material may include spider silk, sheep wool, alpaca or similar materials. Regenerated material is produced by dissolving cellulosic areas of plant fibers in chemicals and re-forming them into fibers (by viscose process (viscose method)). Since regenerated material consists of cellulose like cotton and hemp, it is also referred to as "regenerated cellulose fibers". Regenerated materials may include materials such as rayon and modal (modal), among others.

The synthetic polymeric material may comprise any of a variety of homopolymers or copolymers or a combination of homopolymers and copolymers. For example, the thermoplastic polymer may include a thermoplastic polyurethane homopolymer or thermoplastic polyurethane copolymer, a thermoplastic polyethylene homopolymer or thermoplastic polyethylene copolymer, a thermoplastic polypropylene homopolymer or thermoplastic polypropylene copolymer, a thermoplastic polyester homopolymer or thermoplastic polyester copolymer, a thermoplastic polyether homopolymer or thermoplastic polyether copolymer, a thermoplastic polyamide homopolymer or thermoplastic polyamide copolymer, or any combination thereof. These may include polyethylene terephthalate, ethylene vinyl acetate, homopolymers or copolyesters of nylons such as nylon 6, nylon 11, or nylon 6, among others.

Additionally, in other embodiments, the thermoplastic material comprises a thermoset thermoplastic material (thermosetting thermoplastic material). As described herein, thermoset materials can cure when exposed to specific thermoset conditions at the point of which the thermoset thermoplastic material undergoes a chemical change. Thermoset materials are uncured and thus may be thermoplastic. Cured thermoset materials have undergone chemical changes and are thermoset. Thermoset conditions that trigger the curing of the thermoset thermoplastic material can include a particular temperature, an amount of UV light exposure, actinic radiation, microwave radiation, radio wave radiation, electron beam radiation, gamma beam radiation, infrared radiation, ultraviolet light, visible light, or combinations thereof, among others.

In some embodiments, the thermoset thermoplastic material further comprises a cross-linking agent. As understood in the art, a crosslinker is a chemical product that chemically forms a bond between two hydrocarbon chains. The reaction may be exothermic or endothermic, depending on the crosslinking agent used. Those skilled in the art will be able to select any number of suitable crosslinking agents that will be compatible with the thermoplastic polymer and allow the thermoplastic material to crosslink under desired processing conditions, including temperature, pressure, UV light exposure, and the like.

In some cases, suitable crosslinking agents include homobifunctional crosslinking agents (homobifunctional cross-LINKING AGENT). Homobifunctional reagents consist of the same reactive groups on both ends of a spacer arm (SPACER ARM). Examples of homobifunctional crosslinking agents include dimethyl pimidate dihydrochloride (DIMETHYL PIMELIMIDATE dihydrochloride), bis (N-hydroxysuccinimide ester) 3,3' -dithiodipropionate, bis (3-sulfo-N-hydroxysuccinimide ester) sodium suberate, and others.

In other cases, suitable crosslinking agents include heterobifunctional crosslinking agents. The heterobifunctional crosslinking agent has two different reactive groups, which allows the crosslinking reaction to proceed in a controlled two-step reaction. This can reduce the prevalence of dimers and oligomers in crosslinking. Examples of heterobifunctional crosslinking agents include N-hydroxysuccinimide ester of S-acetylthioglycollic acid, N-hydroxysuccinimide ester of 5-azido-2-nitrobenzoic acid, N-hydroxysuccinimide ester of 4-azidobenzoylmethyl bromide, N-hydroxysuccinimide ester of bromoacetic acid, N- (3-dimethylaminopropyl) -N' -ethylcarbodiimide hydrochloride, N-hydroxysuccinimide ester of iodoacetic acid, and others.

The foamable material of the foamable yarn 102 also comprises a blowing agent. As understood in the art, a blowing agent is a substance that decomposes or vaporizes at an activation temperature to produce a quantity of gas or vapor. Thus, they can be classified as chemical or physical blowing agents. Chemical blowing agents are compounds that can release a gas at their activation temperature. Typically, this released gas does not chemically react with the thermoplastic polymer used as the polymer matrix. The process of releasing gas from the blowing agent is typically exothermic, however, certain compounds that decompose by thermal dissociation, such as bicarbonate, release gas in a reversible and endothermic reaction. Chemical blowing agents can also be sub-classified (subcategorize) as inorganic blowing agents and organic blowing agents. Inorganic blowing agents are mainly used in rubber technology, but can be used in plastic applications to create additional cross-links during the foaming process.

Physical blowing agents are compounds that can change phase to a gas when temperature, pressure, or both temperature and pressure are changed. At a given pressure, the temperature at which the physical blowing agent is converted to a gas is the activation temperature. Physical blowing agents include low boiling hydrocarbons or supercritical fluids.

The choice of blowing agent can affect the quality, density, uniformity and cost of the foamed product. As discussed below, a characteristic property of these compounds is their decomposition temperature, which determines their practical use as blowing agents for a given thermoplastic material and for its processing conditions. In order for the yarn to be able to form a stable foam, the thermoplastic material must be deformable or plastic at the activation temperature of the blowing agent. For this purpose, the deformation temperature of the thermoplastic material may be lower than the activation temperature of the foaming agent.

In some embodiments, the thermoplastic material has a deformation temperature that is greater than about 10 degrees celsius below the activation temperature of the blowing agent. In some embodiments, the thermoplastic material has a deformation temperature that is greater than about 20 degrees celsius below the activation temperature of the blowing agent. In other embodiments, the first thermoplastic material 110 has a softening temperature from about 50 degrees celsius to about 145 degrees celsius.

In some embodiments, the chemical blowing agent has an activation temperature that is at least 5 degrees celsius above the melting temperature of the first thermoplastic material. In other embodiments, the activation temperature of the foaming agent is at least 10 degrees celsius above the melting temperature of the first thermoplastic material. In further embodiments, the activation temperature of the blowing agent is at least 20 degrees above the melting temperature of the first thermoplastic material.

Other properties that may be considered when selecting a chemical blowing agent include affinity for the thermoplastic polymer, maximum yield of gas, activation temperature when the blowing agent evolves gas, rate of gas evolution, toxicity, corrosiveness, odor of decomposition products, impact of decomposition products on color and other physicochemical properties of the thermoplastic polymer, cost, availability, stability to decomposition during storage, and others.

In some embodiments, the foaming agent comprises a chemical foaming agent. In some embodiments, the chemical blowing agent includes sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, calcium azide, azodicarbonamide, hydrazonoformamide (hydrazocarbonamide), benzenesulfonyl hydrazide, dinitroso pentamethylene tetramine (dinitrosopentamethylene tetramine), toluenesulfonyl hydrazide, p' -oxybis (benzenesulfonyl hydrazide), azobisisobutyronitrile, barium azodicarboxylate, or any combination thereof.

In some embodiments, the blowing agent comprises a physical blowing agent. In addition to the partially halogenated fluorochlorohydrocarbons (fluorochlorohydrocarbon), hydrocarbons (e.g., isobutylene and pentane) and inert gases such as carbon dioxide or nitrogen may be used as the hair cutting agent. Inert gases offer many advantages, including low environmentally hazardous output, low gas consumption, increased foam volume per weight of blowing agent used, high cost effectiveness, non-flammability, non-toxicity, chemical inertness, minimal or no residue left in the polymer foam after processing. In addition, carbon dioxide has the advantage of having a higher solubility in many thermoplastic polymers than other inert gases such as nitrogen.

In some embodiments, the blowing agent is present in the first thermoplastic material in an amount effective to foam the first thermoplastic material into a cellular foam structure when the foamable yarn 102 is processed (as discussed in more detail below). The amount of blowing agent can be measured as the concentration of blowing agent by weight in the thermoplastic material. The amount of blowing agent is considered effective when activating the blowing agent results in at least a 10% increase in volume of the thermoplastic material.

In some embodiments, more than one blowing agent may be used. The combination of foaming agents may include at least two chemical foaming agents, at least two physical foaming agents, or a combination of physical and chemical foaming agents. Each blowing agent has an activation temperature at a given processing pressure. These activation temperatures may be about the same or may be different. Processing of the foamable yarn into a cellular foam structure can be performed within a larger temperature operating window by using foaming agents having different activation temperatures. In addition, by controlling the temperature to activate the first blowing agent and then increasing the temperature of the foamable yarn to activate the second blowing agent, a variety of different desired foam structures can be obtained. In some embodiments, the two blowing agents may have activation temperatures that differ by at least about 5 degrees celsius. In some embodiments, the two blowing agents may have activation temperatures that differ by at least about 10 degrees celsius. In some embodiments, the two blowing agents may have activation temperatures that differ by at least about 20 degrees celsius.

A wide range of additives may also be used in the foamable yarn 102. For example, the catalyst accelerates the reaction, or in some cases, lowers the reaction initiation temperature. As discussed above, the blowing agent that forms bubbles in the polymer or polymeric mixture creates a foam. Surfactants may be added to control the size of the bubbles. Other additives that may be used, depending on the application, include cross-linking agents, chain extenders, fillers, flame retardants and coloring materials (such as dyes or pigments), ultraviolet light absorbers, antioxidants, lubricants, plasticizers, emulsifiers, rheology modifiers, fragrances, deodorants or halogen scavengers.

The molecular structure, amount and reaction temperature of each component determine the characteristics of the foamable yarn 102 after processing and subsequent use. Thus, each formulation can be designed with the appropriate ingredients to achieve the desired properties of the final material. As an example, different foaming agents may require additional additives to maintain thermal properties. Finally, after the foamable yarn 102 is processed, the density of the foam is determined by the number and size of the cells, which are at least partially affected by the amount of foaming that occurs during processing. By mixing different combinations of starting materials, the reaction rate and the overall cure rate during processing can be controlled.

In some embodiments, the foamable yarn 102 may include a core having a material different from the foamable material. Advantageously, the core of the foamable yarn 102 may remain substantially intact when subjected to an amount of heat for processing the yarn, such that the core of the foamable yarn 102 may maintain structural integrity even when the foamable material is softened due to its thermoplastic composition being heated, such that the core and/or the processed foamable material (and/or the resulting foam) remain in a desired position. Examples of core materials and structures are described in U.S. provisional application No. 62/937,092, which is incorporated by reference into the above description.

During the manufacture of knitted component 100, at least a portion of foamable yarn 102 may be embedded between certain loops of knitted component 100 on the knitting machine. For example, the foamable yarn 102 can be inserted into the courses of a knitted component during knitting, such as by using an inlay process. For example, the inlay process may include the use of an inlay feeder or other mechanical inlay device (e.g., a combination feeder) on a knitting machine to place the foamable yarn 102 between two needle beds (e.g., a front needle bed and a back needle bed) during the knitting process. An embedding process is described in U.S. patent application publication No. 2013/0145652, published on month 13 of 2013 and having applicant of NIKE, inc. Which is hereby incorporated by reference in its entirety, along with one example of a combination feeder for implementing such a process. While embedding the foamable yarn 102 may be desirable, it is contemplated that the foamable yarn 102 may be attached to the remainder of the knitted component 100 in a different manner, such as by securing the foamable yarn 102 directly to the outer surface of the knitted component 100 using an adhesive, by embroidering or otherwise sewing the foamable yarn 102 so that it extends through the knitted component 100, and so forth. Further, although not shown, it is contemplated that foamable yarns can be included in at least one of the loops forming the courses of knitted component 100.

Still referring to fig. 1, in some embodiments, certain portions of the foamable yarn 102 can be exposed on the outer surface 112 of the knitted component 100. For example, knitted component 100 includes first portion 106 of foamable yarn 102 on surface 112 (e.g., such that it is accessible from an exterior perspective). Similarly, the second portion 108, the third portion 110, etc. are exposed on the outer surface 112. The portion of the foamable yarn 102 between the first portion 106 and the second portion 108 (e.g., the depicted "covered portion 105") may be located below the outer surface 112 such that it is substantially covered by at least one loop of the first yarn 104. Advantageously, and as described in more detail below, such exposure of the foamable yarn 102 can allow for foam protrusions and/or another foam surface property to form on the surface 112, for example, upon post-knitting processing. In some applications, the portion of foamable yarn 102 that remains below surface 112 may be substantially protected from processing stimuli (e.g., heat) because it is covered by loops of knitted component 100. However, the covered portion of the foamable yarn 102 may still be at least partially processed (but in some embodiments, foam expansion may be limited, for example, by the surrounding knit structure). Specific examples of knitting methods for exposing the first portion 106, the second portion 108, etc. on the surface 112 are discussed below with reference to fig. 10-14.

Still referring to fig. 1, more than one embedded foamable yarn 102 may be included (e.g., extending substantially parallel as shown, or not extending substantially parallel). For example, different embedded foamable yarns 102 can extend through different courses of knitted component 100 formed from first yarns 104. Although the foamable yarns 102 are shown in fig. 1 as a uniform yarn type, it is contemplated that different types of foamable yarns 102 may be included. For example, certain regions of knitted component 100 may include yarns having a relatively high density of foamable material per unit length relative to other regions similarly configured from a knitting angle. For example, certain exposed areas (and the resulting protrusions) may be at least 10% more, at least 20% more, at least 30% more, at least 50% more, at least 75% more, at least 100% more, or even more than other exposed areas of the foamable yarn 102. As a result, certain regions may form foam protrusions of different sizes (as discussed below). For example, the foam protrusions 212 may have a height of at least 2mm, such as at least 5mm, 10mm, 20mm, or more. Regarding length and width, the length and/or width of the protrusions may be at least 2mm, such as at least 5mm, 10mm, 20mm or more.

Additionally or alternatively, it is contemplated that different knitting techniques may be used to control the amount of surface exposure of the foamable yarn 102. In fig. 1, for example, the first region 116 of knitted component 100 includes an exposed portion that is longer than an exposed portion in the second region 118. Once processed, the foam protrusions formed in the first region 116 will generally be larger (e.g., at least longer) in at least one dimension than the foam protrusions formed in the second region 118, as more foamable material is exposed on the surface 112 in the first region 116 relative to the second region 118.

Fig. 2 shows an example of an article 200 that may be initially formed as a knitted component in a manner similar to knitted component 100 depicted by fig. 1. Referring to fig. 2, an article 200 may generally include five (5) zones. The first region 202 may include more than one foam protrusion 212. Foam protrusions 212 may include a porous foam formed as a reaction product of foaming foamable yarns 102, such as described above. In particular, referring to the exposed portions 106, 108, etc. of fig. 1, the exposed portions can be exposed to a particular amount of heat and/or another stimulus to activate the foamable material after forming the knitted component 100 of fig. 1. Specific activation parameters are described in detail in U.S. provisional application No. 62/937,092, which is incorporated by reference above. When activated, the foamable material may expand (e.g., away from surface 112 of fig. 1) and then cure or harden in an expanded state (or otherwise attain a relatively permanent material state) as it is allowed to cool. The resulting structure may be protrusions, such as foam protrusions 212 forming a specific surface topography.

As shown in fig. 2, the first region 202 may include protrusions 212 of substantially the same size, but this is optional. The first region 202 can optionally have a variable amount of foamable material exposed on the surface of the knitted component and/or the processing program in different regions of the first region 202 can be altered such that the protrusions 212 are varied. For example, the protrusions 212 may form a surface pattern optimized for a particular function.

The second region 204 of fig. 2 is similar to the first region 202, but the protrusions 212 are slightly smaller. This may be achieved by changing the knitting process (e.g., by exposing less foamable yarn inserts on the surface) and/or by switching the type of foamable yarn during knitting. Similarly, the fourth region 208 and the fifth region 210 include protrusions 212 that are relatively spaced apart (e.g., by separating exposed portions of the embedded foamable yarns) and are relatively low in height, respectively. A variety of additional patterns and/or alternative patterns may be used. Furthermore, while all of the protrusions 212 in fig. 2 are substantially hemispherical in shape, it is contemplated that the shape of the protrusions 212 may be altered by the use of specific knit structures, specific material types, by the use of a molding press or other similar device during the foam activation step, or by any other suitable method.

The third region 206 of fig. 2 includes a foam surface 222 that is formed substantially from foam (e.g., the reaction product of the foamable yarn 102). Foam surface 222 may be formed by a variety of methods. For example, the foamable material used in the foamable yarn may have a sufficiently high concentration such that once it is processed and assumes an expanded state, the foam completely covers the outer surface of knitted component 100. Alternatively, and as discussed in more detail below, it is contemplated that a unique knitting process may be used such that most or all of the surface 222 is formed from foamable yarns 102 having less foam expansion (see, e.g., fig. 12 and related description).

Fig. 3-7 illustrate various embodiments of an article 200 formed using the methods and processes described herein. For example, fig. 3 shows an article 200 having relatively small foam protrusions 212, the foam protrusions 212 extending from the surface 112 of the knitted component 100. As discussed above, locations between foam protrusions 212 may include embedded yarns with foamable material, e.g., such that foamable material and/or foam extends from one protrusion 212 through knitted component 100 to the next protrusion 212. While the protrusions of fig. 3 are substantially the same size, they may vary (e.g., due to the use of different yarns and/or by exposing different lengths of yarns comprising foamable material during knitting). While foam protrusions 212 are shown on only one side of the fabric, they may additionally or alternatively be on the other side.

Fig. 4 shows an article 200 having a foam surface 222 or a surface substantially covered with a porous foam. Such embodiments may be formed by using a sufficient amount of foamable material within the yarn such that once the yarn expands due to, for example, post-knitting processing, the yarn substantially covers the knitted loops. While in the depicted embodiment the foam surface 222 is formed on only one side of the article 200, the opposing surface 224 may additionally or alternatively be covered in foam (e.g., once the knitted component is processed such that the foamable yarn forms a foam).

Fig. 5-6 are similar to fig. 3, but the foam protrusions are of a different size. For example, in fig. 5, foam protrusions 212 are approximately the same height as foam protrusions 212 of fig. 3, but they are longer (e.g., because the foamable yarns are exposed for a longer distance). In fig. 6, the foam protrusions are substantially higher than those of fig. 3 or 5. This may be achieved by using a foamable yarn with more foamable material per unit length and/or by differently processing the foamable yarn to obtain a relatively high degree of expansion.

Fig. 7 shows a different embodiment in which a porous foam 400 is located between a first layer 402 and a second layer 404 of knitted component 100. For example, foamable yarns (as described above) may be embedded through an area having a tubular knit construction in which the first layer 402 and the second layer 404 are formed. In particular, the first layer 402 may include more than one course formed by intermeshed loops (e.g., of the "first yarn" described above), and similarly, the second layer 404 may include more than one course formed by intermeshed loops. The pocket 408 may be formed between the first layer 402 and the second layer 404, particularly where the loops of the first layer 402 are not directly connected to the loops of the second layer 404 (e.g., are not looped with the loops of the second layer 404). The pocket 408 may even exist prior to post-knitting processing and the foamable yarn may be located therein as a result of the embedding procedure. Once heated or otherwise processed, the foamable material of the foamable yarn can expand to fill the pocket 408. For example, such an embodiment is advantageous for providing a foam pad within a knitted structure, although other functions and/or uses are additionally or alternatively contemplated.

The methods and features discussed above may be incorporated into any suitable article. For example, fig. 8 illustrates an upper 300 for an article of footwear that includes more than one foamable yarn 102. Upper 300 is shown in a pre-manufactured state in fig. 8 (e.g., after the knitting process and prior to forming foam protrusions). As shown, embedded foamable yarns 102 may be exposed on exterior surface 320 of upper 300 in selected locations. Any suitable location may be selected, such as in midfoot region 324 and toe region 326 in the depicted example (which is for illustration only). Advantageously, foam protrusions, once formed, may provide suitable surface characteristics on exterior surface 320 of upper 300. Without limitation, the foam protrusions may form gripping elements (GRIPPING ELEMENT) (e.g., suitable for playing a soccer ball with a high degree of rotation for gripping a rope, rock wall, or other object, etc., during a particular athletic competition). If a relatively soft foam is used, it is also contemplated that foamable yarn 102 may be exposed on interior surface 328 of upper 300 to provide cushioning and/or other comfort characteristics.

Fig. 9 illustrates another embodiment of upper 300, wherein upper 300 is in a configuration that it may have just after knitting (and/or post-knitting processing) but before being folded or otherwise manipulated into a wearable shape. As shown, upper 300 may include multiple areas with different surface characteristics (e.g., similar to the embodiment of fig. 2). The surface features are formed by foam protrusions 212 and/or foam surface 222. As shown, the upper may include a first region 306, the first region 306 having a set of foam protrusions 212 that cover a toe region 326. Second region 308, located in midfoot region 324 of the upper, may include larger foam protrusions 212. Third region 310 may include a surface formed substantially of porous foam (as discussed above), which may be advantageous to provide cushioning where the fastening system is located (e.g., where the lace is tightened over throat area 332 of upper 300). Heel region 330 includes fourth region 312 having relatively small foam protrusions 212. Notably, certain regions may lack protrusions, regions may be reorganized, and so forth.

Fig. 10-13 illustrate certain examples of knitting techniques that may be used to expose certain portions of the embedded foamable yarns on the surface of the knitted component. As shown by fig. 10, for example, an inlaid jacquard process (inlay jacquard procedure) may be used to embed the foamable yarn 102 within the loops of the first yarn 104 (e.g., including polyester and elastane (elastane) in the depicted embodiment, although other suitable yarn types are also contemplated). As shown, a unique transfer process T (transfer process T) can be used, which is critical to ensure that a length of foamable yarn 102 will be exposed on the resulting surface. In particular, transfer T causes some loops of a course that would otherwise cover foamable yarn 102 (e.g., where it is ultimately exposed) to be moved onto an opposing needle bed, thereby providing an aperture or "opening" in which more than one needle is skipped on one needle bed (e.g., such that nothing covers embedded foamable yarn 102).

The resulting exposed length of the foamable yarn 102 can be equal to or greater than, for example, the length of a portion of a knitted course comprising at least two consecutive loops, and can be much greater (e.g., at least three, four, five, ten, fifteen, or even twenty or more consecutive loops). In metric units, the exposed length may be, for example, equal to at least 2mm, and potentially much greater (e.g., about equal to or greater than 5mm, 10mm, 20mm, or more). The process of fig. 10 may correspond to, for example, the first region 202 of fig. 2. Fusible yarn 140 may additionally be included, for example, the fusible yarn 140 may cover and then "release" certain portions of the foamable yarn 102 (as described with reference to fig. 12). Fusible yarn 140 may additionally or alternatively be included to provide stiffness, strength, and/or other advantageous characteristics to the knitted component once processed with heat (e.g., which may be the same heat used to activate the foamable yarn).

Fig. 11 and 13-14 illustrate a process by which a knitted structure similar to that formed, for example, by fig. 10 may be formed, and the general principles for forming the exposed portions of the foamable yarn 102 remain the same (e.g., by using transfer T). In particular, fig. 11 and 13-14 may correspond to regions 204, 208, and 210, respectively, of fig. 2. However, those skilled in the art will appreciate that many variations can be made to provide knitted components with optimal characteristics. For example (and without limitation), other yarns may be included, such as the high tenacity yarn 103 shown in fig. 11, which may provide a high degree of strength and stiffness.

Fig. 12 is a knitting procedure that may be used to form a surface that is formed entirely or substantially of foam (e.g., once processed). In fig. 12, foamable yarn 102 is embedded between courses formed of a first yarn 104 (e.g., polyester or other high melting point yarn, such as potentially including elastic fibers) and a fusible yarn 140 (e.g., formed of a thermoplastic material having a relatively low melting point suitable for thermal processing). Uniquely, the only loops formed on the front side of the embedded foamable yarn 102 are formed solely by the fusible yarn 140. Once removed from the knitting machine, the resulting knitted component may appear similar to other knitted components described using the knitting process described above. However, once heated, the fusible yarn 140 may substantially melt or completely melt, allowing the foamable material of the foamable yarn 102 to "release" due to deformation of the fusible yarn 140. Thus, the foamable material may substantially or completely cover the respective sides of the fabric, thereby forming a foam surface similar to that described above (e.g., see third region 206 of fig. 2 and third region 310 of fig. 9).

While various embodiments of the present disclosure have been described, the present disclosure is not limited, except in accordance with the appended claims and their equivalents. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims. Furthermore, the advantages described herein are not necessarily the only advantages of the disclosure, and it is not necessarily expected that each embodiment of the disclosure will achieve all of the described advantages.

The subject matter of the present disclosure may also relate to the following aspects, among others:

in aspect 1, a knitted component includes a first region,

Wherein the first region includes more than one knitted loop including a first yarn, and a second yarn at least partially embedded within the first region of the knitted component such that the second yarn extends between at least a first loop and a second loop of the more than one knitted loop, wherein the second yarn includes a foamable material including a blowing agent and a thermoplastic polymer.

Aspect 2 includes the knitted component of aspect 1, wherein the second yarn includes a first portion exposed on the first surface in the first region.

Aspect 3 includes the knitted component of aspect 2, wherein the first portion has a length that is greater than or equal to a length of a portion of a first course that includes at least three consecutive knitted loops, the first course being in the first region.

A4 th aspect includes the knitted component of aspect 2, wherein the second yarn additionally includes a second portion exposed on the first surface in the first region, and wherein the second yarn includes a covered portion extending from the first portion to the second portion.

Aspect 5 includes the knitted component of aspect 4, wherein the second portion has a length that is greater than a length of the first portion.

A 6 th aspect includes the knitted component of aspect 2, wherein a second course extends through a second area having a second surface, wherein the second yarn is at least partially embedded within the second course, and wherein the second yarn includes a second portion exposed on the second surface in the second area.

Aspect 7 includes the knitted component of aspect 6, wherein the second portion of the second yarn includes a length that is greater than a length of the first portion of the second yarn.

Aspect 8 includes the knitted component of any of aspects 1-7, wherein the first region comprises a tubular knitted construction having a first layer and a second layer, wherein at least one of the first layer and the second layer comprises the first yarn, and wherein at least a portion of the second yarn is located within a pocket between the first layer and the second layer.

Aspect 9 includes the knitted component of any one of aspects 1-8, further comprising a third yarn included in at least one loop of the first course, wherein the third yarn comprises a second thermoplastic polymer, and wherein the second thermoplastic polymer has a melt temperature of about 120 ℃ or less.

The 10 th aspect includes a knitted component comprising a first region having a first surface, wherein the first region is at least partially formed from a first knitted course having more than one loop formed from a first yarn, and a porous foam material at least partially surrounding the first yarn in the first region of the knitted component, wherein the porous foam material forms a first protrusion extending from the first surface of the first region.

Aspect 11 includes the knitted component of aspect 10, wherein the at least one projection comprises a height of at least 2 mm.

Aspect 12 includes the knitted component of any one of aspects 10-11, wherein the porous foam material is a reaction product that foams at least a portion of a second yarn, the second yarn comprising the first thermoplastic material.

Aspect 13 includes the knitted component of any one of aspects 10-12, wherein the at least one projection has a length of at least 5mm.

The 14 th aspect includes the knitted component of any one of aspects 10-13, wherein the at least one protuberance comprises a first foam protuberance and a second foam protuberance, and wherein the second foam protuberance comprises at least 20% more of the porous foam material by mass than the first foam protuberance.

The 15 th aspect includes the knitted component of any one of aspects 10-14, wherein the at least one projection comprises a first foam projection and a second foam projection, and wherein a covered portion of a second yarn extends from the first foam projection to the second foam projection, the covered portion comprising at least one of the porous foam material and a foamable material with a foaming agent.

Aspect 16 includes the knitted component of any one of aspects 10-15, wherein the covered portion of the second yarn is embedded through the knitted component.

Aspect 17 includes the knitted component of any one of aspects 10-16, further comprising a third yarn included in at least one loop of the first knitted course, wherein the third yarn comprises a second thermoplastic polymer material, and wherein the second thermoplastic polymer material has a melting temperature of about 120 ℃ or less.

Aspect 18 includes a method comprising knitting a course with a first yarn, wherein the course includes more than one loop, at least partially embedding a foamable yarn within the first course, and transferring the loops of the first course from one needle bed to another needle bed such that at least a portion of the foamable yarn is exposed on a surface of a resulting knitted component.

Aspect 19 includes the method of aspect 18, further comprising heating the knitted component such that the foamable yarn forms at least one foam protrusion on a surface of the knitted component.

The 20 th aspect includes the method of any of aspects 18-19, further comprising knitting at least one loop with a fusible yarn separate from the foamable yarn, and further comprising heating the fusible yarn such that the fusible yarn deforms when the foamable material of the fusible yarn expands.

Claims

1. A knitted component, comprising:

a first region and a second region, wherein the first region and the second region include more than one knitted loop comprising a first yarn; and

a second yarn at least partially embedded in the first region and the second region of the knitted component such that the second yarn extends between at least a first knit loop and a second knit loop of the more than one knit loops,

wherein the second yarn comprises a core material and a foamable material comprising a foaming agent and a thermoplastic polymer, and comprises a first portion exposed on a surface of at least a portion of the first region and a second portion exposed on a surface of at least a portion of the second region,

wherein the foamable material of the second yarn has at least partially expanded to form more than one foam protrusion on the surface of at least a portion of the first region and on the surface of at least a portion of the second region, and

Wherein at least a portion of the more than one foam protrusions in the first region are different in size and/or shape and/or spacing compared to at least a portion of the more than one foam protrusions in the second region.

2. The knitted component according to claim 1, wherein the first portion has a length equal to the length of a portion of a first row comprising at least three consecutive knit loops, the first row being in the first area.

3. A knitted component according to claim 1, wherein the second yarn further includes a second portion exposed on the surface in the first area, and wherein the second yarn includes a covered portion extending from the first portion in the first area to the second portion in the first area.

4. The knitted component according to claim 3, wherein a length of the second portion in the first area is greater than a length of the first portion in the first area.

5. The knitted component of claim 1, wherein a second row extends through the second region, wherein the second yarn is at least partially embedded within the second row.

6. The knitted component of claim 5, wherein the second portion of the second yarn in the second area comprises a length that is greater than a length of the first portion of the second yarn in the first area.

7. A knitted component according to claim 1, wherein the first area comprises a tubular knitted structure having a first layer and a second layer, wherein at least one of the first layer and the second layer comprises the first yarn, and wherein at least a portion of the second yarn is located in a pocket between the first layer and the second layer.

8. The knitted component according to claim 1, further comprising a third yarn included in at least one knit loop of the first row, wherein the third yarn comprises a second thermoplastic polymer, and wherein the second thermoplastic polymer has a melting temperature of 120°C or less.

9. A method for preparing a knitted component according to any one of claims 1 to 8, comprising:

knitting a course with the first yarn, wherein the course includes more than one loop in a first region and a second region;

causing the second yarn to be at least partially embedded within the course, wherein the second yarn is a foamable yarn comprising a core material and a foamable material comprising a blowing agent and a thermoplastic polymer; and

transferring the loops of the course from one needle bed to another needle bed so that a first portion of the foamable yarn is exposed on the surface of at least a portion of the first area of the resulting knitted component and a second portion of the foamable yarn is exposed on the surface of at least a portion of the second area of the resulting knitted component,

Processing the knitted component, wherein the exposure of the second yarn allows the second yarn to at least partially expand to form more than one foam protrusion on the surface of at least a portion of the first area and on the surface of at least a portion of the second area, and wherein at least a portion of the more than one foam protrusion in the first area is different in size and/or shape and/or spacing compared to at least a portion of the more than one foam protrusion in the second area.